Tube Expander Design & Usage

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© 2007 Elliott Tool Technologies
Choosing The Right Tube Expander To
Meet Your Needs

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Heat Exchanger Expander Needs Assessment

• Tube material.
• Tube OD.
• Tube wall thickness (BWG).
• Tube sheet thickness.
• Any obstructions - waterbox or
channel plate, tube
projections, etc.

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Calculating The Rolled Inside Diameter

• Rule of thumb: the harder the material, less wall

reduction required.
• Percent wall reduction guidelines:
• Copper & cupro-nickel – 8% to 10%
• Steel, carbon steel, admiralty brass – 7% to 8%
• Stainless steel, titanium – 4% to 5%
• 3003 or 4004 aluminum – 5% maximum
• 6061T aluminum – 10% to 12%

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Determining 3, 4 or 5 Roll Expander Design

• Generally a 3 roll expander is well suited but inquire about:

• Tube material:
• Stainless steel, titanium:
• Work – hardening materials.
• Minimum 4-roll design, if possible.
• Wall thickness:
• 20 gage (.035”) & thinner:
• Stainless steel, titanium – 5 roll preferred.
• Carbon steel, brass, copper, aluminum – 4 roll preferred.
• Tube pitch:
• Tube sheets with thin ligaments in a triangular tube pitch pattern may be disrupted
using a standard 3 roll expander.

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When To Use 4 Or 5 Roll Expanders

• Tube materials:
• Stainless steel.
• Titanium.
• Other exotic alloys.
• Materials that work harden rapidly.
• Tube sheets with thin ligaments in a triangular pitch.

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Other Factors That May Effect Expander Design

• Flush, recess, telescoping or friction collar?

Flush Collar Friction Collar

• Tube bend.

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When Is The Reach Of An Expander Important?

• When the depth of the tube

sheet is greater than the
effective roll length.
• For double tube sheets.
• Fin fan coolers.

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Importance Of Sealing Full Length Of Tube Sheet

• No matter the method, seal the full length of tube sheet.

• If less than full length, medium is condensed and trapped between
tube and tube sheet. This will lead to premature seal deterioration
and tube decay.
• If tube is expanded beyond tube sheet thickness, tube bulging
creates a sharp edge which weakens the tube.

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Improving Tube Expansion Quality &
Maximizing Tool Life

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How A Mechanical Bond Is Formed
• Tube Joint formed by compressing the tube into a
fixed container (i.e. tube sheet).
• Ideally rolled joint created when the tube state
turns to plastic (stays where it stops) and is
contained by the tube sheet’s elastic properties
(fully recovers). This has to occur right before the
tube sheet turns to a plastic state.
• Under-rolling occurs when the tube is not
compressed enough and remains at an elastic
stage. Bond is not created as yield of material is
not compressed enough to turn tube sheet to
elastic.
• Over-rolling occurs when tube surpasses the
elastic property of tube sheet and therefore the
ligaments between tube sheet holes are shifted
causing adjacent tubes to leak.

Tube: Plastic
Tube Sheet: Elastic
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Common Causes Of Tube Joint Failure

• Not enough tube expansion (under rolling).

• Too much tube expansion (over rolling).
• Dirty, scratched tubes or tube sheets.
• Dents or other imperfections of the tube.

Over-Rolled Joint

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Calculating The Rolled Inside Diameter

• Percent tube wall reduction guidelines:

• Rule of thumb: Harder the material, less wall reduction required.
• Copper & Cupro-Nickel – 8% - 10%
• Steel, Carbon Steel, Admiralty Brass – 7% - 8%
• Stainless Steel, Titanium – 4% - 5%
• The above are guidelines and may not apply specifically
to your design requirements.

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Rolled ID Calculation
Flange /
Fitting Hole
Tube O. D.

Tube
I. D.

Tube Wall
Thickness

Step Step Description Example

A Measure Flange / Fitting Hole 0.760
Tube B Measure Tube O. D. 0.750
Example C Calculate Clearance (A-B) 0.010
¾” 16 Ga. D Measure Tube I. D. 0.620
Brass E Calculate Total Tube Wall Thickness (B-D) 0.130
Tube F Calculate Wall Reduction (7%) 0.009
G Calcualte Finished Rolled Tube I. D. (C+D+F) 0.639

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Expansion Calculation Tool Is Available From Elliott

ID Range

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Proper Operation For Effective Joints & Tool Life

Visual Inspection

• The tube surfaces must be clean of debris, scratches,

dents, cracks and any other imperfections of the tube.
• Inspect the tube sheet where tube is being expanded
into, for any radial or longitudinal imperfections.

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Proper Operation For Effective Joints & Tool Life

• The expander must also be clean and free from debris.

• Any visible signs of wear on the expander’s rolls and
mandrel - replace these items immediately.
• The expander must have the rollers and mandrel well
lubricated to prolong tool life.
• The kind of lubricant will make a difference. Use Elliott
recommended!
• The expander’s thrust bearings must have liberal
amounts grease to reduce friction. (Extremely important
if rolling the joint to a torque).

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Tips To Improve Tool Life
• Use 2 Expanders alternatively for one operator. Place one expander in
lubricant while the other one is under rolling operation.
• Exchange expander about every 50 joints to allow for proper cool-off and
lubrication. Use Quick Change Chuck to minimize downtime.
• Every 5-7 complete exchanges, check for debris trapped between mandrel
and rolls. Disassemble and clean if required. Ensure thrust bearings have
liberal amounts of grease.
• Roll to suggested tube wall reduction using a Torque Control Box. This
ensures repeatability of Joint Tightness and reduces overheating of tube
expander and components.
• Hold Rolling Motor in a vertical / straight position and avoid motor to weigh
on the mandrel to avoid possible axial load on the mandrel creating fatigue
and premature tool breakage.
• Use double-radius rolls when rolling inside the tube sheet (or inner-sheet).
This will avoid sharp edges inside the tube that will cause strain on the
mandrel when withdrawn.

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